Automatic Manual Chargers

Battery Chargers
SERVICE MANUAL / PARTS LIST

AUTOMATIC Advance MODELS 56206980, 56206981, 56372947, 56388109,
56395101, 56388502, 56388120, 56409494, 56411058, 56411643, 56409788,
56205983, 56412272, 56206973, 56372203, 56372190, 56388119
Lester MODELS 56031407, 56632342, 56638431, 56638436, 56638439,
56638440, 56632293, 56031403, 56031405, 56031408
MANUAL MODELS (obsolete) 56206975, 56372945, 56372955
Revised 8/00 Form Number 56041170
FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 45

BATTERY CHARGER SERVICE MANUAL / PARTS LIST
_______________________________________________________________________________________
TABLE OF CONTENTS
Safety ......................................................................................................................... 2
General Information .................................................................................................... 3
Transformer / Rectifier or Power Section.................................................................... 3
On / Off Control Section ............................................................................................. 4
Automatic and Manual Timer Battery Charger Troubleshooting ................................. 5
Manual Charger PN 56206975 ................................................................................. 16
Automatic Chargers PN 56206980 ........................................................................... 17
Automatic Charger PN 56372947............................................................................. 19
Automatic Charger PN 56395101 (replaces PN’s 56372947 & 56395347) .............. 22
Automatic Charger PN 56411058 ............................................................................. 26
Automatic Charger PN 56205983 (replaces PN 56206981)..................................... 29
revised 8/00
BATTERY CHARGER SERVICE MANUAL
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
SYMBOLS
Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this informa-
tion carefully and take the necessary steps to protect personnel and property.
DANGER!
Is used to warn of immediate hazards that will cause severe personal injury or death.
WARNING!
Is used to call attention to a situation that could cause severe personal injury.
CAUTION!
Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other
property.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
GENERAL SAFETY INSTRUCTIONS
DANGER!
HIGH VOLTAGE! With the charger on, the internal charger capacitor voltage is approximately 650
volts.
WARNING!
Do not operate the charger if it is malfunctioning. Personal injury or property damage could result.
Remove all jewelry when working near electrical components.
CAUTION!
To be able to use the troubleshooting guide safely and effectively it is important to read this manual
completely before beginning any tests.
Incorrect assembly may result in a risk of electric shock or fire.
Always unplug the electrical cords, first from the AC outlet and then from the charger receptacle
before attempting any repairs or service to the charger.
REPAIRS BY QUALIFIED PERSONNEL ONLY. NOTE: Modifying this charger for use other than that
for which it was intended, repairs by persons not qualified, or not using original equipment replace-
ment parts will void the manufacturer’s warranty and liability.
2 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
GENERAL INFORMATION
The Nilfisk-Advance Battery Chargers are designed to recharge deep-cycling lead acid batteries. A
ferroresonant transformer is used to provide a highly reliable, line compensating unit with a minimum of
moving parts, designed for long trouble-free service. The chargers are constructed so that all parts can be
tested and replaced with basic hand tools. In addition, an analog multimeter of 10,000 ohms per volt sensitivity
or better is required.
The Nilfisk-Advance battery charger is comprised of two basic sections; the transformer/rectifier or power
section, and the on/off control section.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
TRANSFORMER / RECTIFIER OR POWER SECTION
The power or charging section consists of a transformer with its specified part number and rating capacitor and
rectifying diodes attached to a heat sink. The ammeter displays charging current and the fusing provides
electrical protection.
The transformer consists of primary coil or coils separated from the capacitor and secondary coils by a stack
of transformer grade steel pieces called a shunt pack. The transformer coils are wound with high temperature
double insulated magnet wire. The leads are covered with tan or black sleeving and all termination connectors
are crimped and soldered. The transformer must be properly connected in accordance with the correct wiring
diagram for each specific part number charger.
The capacitor functions in combination with the specific transformer to provide the correct charger output with
variation in AC line voltage. The correct part number and rating capacitor as listed on the parts list must be
used with the correct part number transformer and charger.
CAUTION!
Use only the correct part number and rating capacitor. Use of a different capacitor may result in
improper charging, capacitor failure, transformer burnout and / or battery damage.
The rectifier diodes are attached to a heatsink plate or bracket that is fastened to, but electrically isolated from,
the charger chassis. Connection points are provided on the heatsink assembly with diodes. One connection
point is to the heatsink plate itself or a tab attached to it, the remaining connections are to individual diode tabs
or leads. More than one lead can be attached to each connection point and the heatsink assembly with diodes
must be the right part number and connected in accordance with the correct wiring diagram for the specific
part number charger.
The ammeter needle deflects in response to current flow indicating charge current. Connections to the
ammeter terminals are either push on or with jam nuts. When tightening the jam nuts, insure the threaded stud
does not turn, or damage to the ammeter can occur. Use only the correct ammeter as specified in the appro-
priate wiring diagram and parts list.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
TRANSFORMER / RECTIFIER OR POWER SECTION (continued)

The fusing consists of a fuse link in series with each diode and provides overcurrent protection should one or
both diodes fail in the shorted mode. When both fuses or fuse links blow, this is usually due to a reverse
polarity connection to the batteries. Either two individual fuseholders with fuses or a single dual element fuse
assembly provides this protection. The fuse assembly consists of a double ended fuse wire visable through a
transparent bubble mounted on the front panel. Each half of the fuse wire serves as an individual fuse ele-
ment. After correcting the reason for the fuse blowing, replace the fuse or fuse assembly only with the correct
rating and part number in accordance with the correct wiring diagram and parts list for the specific part number
charger.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
ON/OFF CONTROL SECTION
The ON/OFF control is provided by either a manually set hours of charge timer or the fully automatic battery
condition sensing electronic timer kit.
The fully automatic timer section has three main components.
The, “Electronic Timer Kit”, consist of state of the art electronic circuitry on a printed circuit board contained in
a protective sheet metal housing.
The “Control Cable Assembly”, has a polarized edge connector that mates with the circuit board pads on the
rear of the electronic timer kit. The wires attached to the edge connector are the correct length, position and
color to be connected in accordance with the proper wiring diagram for each specific part number charger.
The “On/Off Control Relay”, responds to signals from the electronic timer kit to either turn the AC power on or
off to the transformer of the power section. The relay terminal nomenclature is printed on each relay case and
should be connected according to the correct wiring diagram for each specific part number charger.
The manually set hours of charge timer is a simple electric clock motor operated on/off switch that turns off
after the preset number of hours has elapsed. The push on connections are numbered and must be con-
nected according to the correct wiring diagram for each specific part number charger.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
AUTOMATIC TIMER BATTERY CHARGER TROUBLESHOOTING
Proper functioning of the Automatic Battery Charger is indicated by the following sequence of events. Three to
five seconds after the DC plug is connected to the charger receptacle the control relay “clicks” on, the trans-
former hums and the ammeter registers proper charge.
Proper diagnosing and repair requires identifying the malfunction from the following list, performing the indi-
cated tests and repairing or replacing the malfunctioning items.
Malfunction Descrip1ion Test Procedures / Section Number
Relay does not “click” on when DC plug is Test for complete electrical connection to
connected to the charger receptacle. batteries / 1.
Test for proper functioning of automatic timer
components / 2.
Relay “clicks” on, but transformer does not Test AC power circuit / 3.
hum.
Transformer hums but no ammeter indication. Test Charger DC Circuit / 7.

Test Fuses and Diodes / 6.
Test Capacitor / 4.
Test Transformer / 5.
Transformer hums but charger output is low. Test Fuses and Diodes / 6.
Fuse blows as soon as DC plug is connected Test Charger DC Circuit / 7.

to the charger receptacle. Test Fuses and Diodes / 6.
Ammeter remains pegged at maximum Check Battery System Voltage / 8.

charge for more than 30 minutes.
Charger does not turn off. Test Automatic Timer Section for “Does Not
Turn Off” / 9.
WARNING!
Do not touch the battery terminals or contacts on the charging plug. An electrical shock could result.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
MANUAL TIMER BATTERY CHARGER TROUBLESHOOTING
Proper functioning of the charger is indicated by the following sequence of events. When the timer knob is
turned to “ON”, the transformer hums and the ammeter registers proper charge.
Proper diagnosing and repair requires identifying the malfunction from the following list, performing the indi-
cated tests and repairing or replacing the malfunctioning items.
Malfunction Description Test Procedures / Section Number
Transformer does not hum when the timer is Test AC Power Circuit / 3.
turned to “ON”.
Transformer hums but no ammeter indication. Test for complete electrical connection
to battery system / 1.
Test Charger DC Circuit / 7.
Test Fuses and Diodes / 6.
Test Capacitor / 4.
Transformer hums but charger output is low. Test Fuses and Diodes / 6.
Fuse blows as soon as the charger is Test Fuses and Diodes / 6.

connected to the batteries.
Ammeter remains pegged at maximum charge Check Battery System Voltage / 8.

for more than 30 minutes.
Charger does not turn off. Replace Manual Timer.
WARNING!
Do not touch the battery terminals or contacts on the charging plug. An electrical shock could result.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
1-CHECKING FOR COMPLETE ELECTRICAL CONNECTION TO THE BATTERIES
A Measure and record battery system voltage at the battery posts of the machine. Connect the positive (+)
voltmeter lead to the positive (+) battery system post and the negative (-) voltmeter lead to the negative
(-) battery system post.
B Measure and record battery voltage at the charger receptacle. If no voltage is measured or the voltage
measured is lower than the voltage measured in step A, repair or replace connections to batteries in
machine.
C See Figure 1. With both the AC cord and the charging plug disconnected, remove the cover from the
charger. Connect the positive voltmeter lead to the same point inside the charger where the white (+) DC
cord lead connects. Connect the negative voltmeter lead to the same point inside the charger where the
black (-) DC cord lead connects.
FIGURE 1. Testing for complete electrical connection to the battery system.
D Connect the DC Output cord to the charger receptacle and record the voltage measured. It should be the
same voltage as measured in step A.
E If no voltage is measured or the voltage measured is lower than the voltage measured in step A, repair or
replace the receptacle, charger plug and / or the cordset and re-test.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
2-TEST FOR PROPER FUNCTIONING OF AUTOMATIC TIMER COMPONENTS
A With both the AC cord and the charging plug disconnected, remove the cover from the charger. Verify
that the charger is wired correctly according to appropriate wiring diagram for the specific part number
charger.
B Remove the retaining screws and slide the

automatic timer kit out the front of the
charger. Disconnect the edge connector
from the automatic timer kit and insert the
test kit (Fig. 2). Connect the DC plug to the
charging receptacle and listen for the relay
to “click” on. If the relay now “clicks” on,
install a new automatic timer kit and re-test.
If the relay does not “click” on, continue with
the next test.
FIGURE 2. Insert the test kit.
C Measure DC voltage across the pads on the

test kit that the red (Positive) and black
(Negative) wires contact (Fig. 3). The meter
should read the same battery voltage as
recorded in 1-C. If no voltage is measured
or the voltage measured is lower, repair or
replace the control cable assembly and
retest.
D Measure DC voltage across the pads on the

test kit that the black (Negative) and brown
(Positive) wires contact. It should read the
same battery voltage as recorded in 2-C. If
no voltage is measured install a new control
relay and retest.
FIGURE 3. Measure battery system voltage

at the test kit pads.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
3-TEST AC POWER CIRCUIT
A Measure AC line voltage at the outlet to be sure the correct AC voltage for the specific part number
charger is present (115 VAC, or 230 VAC). If the correct AC power is present, disconnect the AC plug
and the charging plug.
B Adjust the multimeter to the low resistance scale (R X 1) or use a low voltage continuity tester. Connect
the tester leads to the flat prongs on the AC plug.
• MANUAL TIMER CHARGER

Turn the timer knob to “ON” and note the response. The circuit should be complete when the timer knob
is turned to “ON”, (Fig. 4) and open when the timer knob is turned to “OFF”.
FIGURE 4. Test AC circuit for continuity.
• AUTOMATIC TIMER CHARGER

Connect the charging plug to the charging receptacle and listen for the control relay to “click” on, 2 to 5
seconds after connection.
• The circuit should be open before the relay “clicks” on and the circuit should be complete after the relay
“clicks” on.
C If the circuit does not test as described, individually check the AC cord, manual timer contacts, control
relay contacts, primary transformer coil(s) and all connections.
DANGER!
HIGH VOLTAGE! With the charger on, the charger capacitor voltage is approximately 650 volts AC.
Use extreme caution when working near the capacitor terminals.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
4-TEST THE CAPACITOR
WARNING!
It is possible for the capacitor to not be fully discharged. To test for this, adjust your meter to the
highest DC voltage scale and touch the test leads to the capacitor terminals and note the reading. If
the meter needle deflects in the wrong direction reverse the test leads and repeat. If the capacitor was
not fully discharged a voltmeter reading will indicate this. Continue holding the voltmeter leads on the
capacitor terminals until the voltage reading drops to zero.
A Using the analog ohmmeter adjust the scale to R X 10,000 (1 Ok) Ohms. Loosen the capacitor clamp
and carefully remove both transformer leads from the capacitor terminals so the wires do not break.
Touch the ohmmeter leads to the capacitor terminals and note the results. Reverse the test leads, repeat
the test and compare to the following:
• GOOD CAPACITOR: When the ohmmeter leads are connected to the capacitor terminals the meter
needle bumps up to mid scale and quickly coasts back to high resistance (∞).
• OPEN CAPACITOR: When the ohmmeter leads are connected to the capacitor the meter needle does
not move and stays at high resistance (∞). A bulge in the top of the capacitor may be visable if the
capacitor has failed “OPEN”.
• SHORTED CAPACITOR: When the ohmmeter leads are connected to the capacitor terminals, the meter
needle jumps to full scale, zero ohms and remains there.
B If the capacitor is “Open” or “Shorted” it must be replaced.
CAUTION!
Use only the correct part number and rating capacitor as specified on the correct parts list for the
specific part number charger. The use of a different part number or rating capacitor may result in
improper charging, capacitor failure, transformer burnout, and / or battery damage.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
5-TRANSFORMER TESTING
Testing the transformer consists of measuring the AC voltage across the transformer secondary leads that
connect to the diodes. This voltage is measured first with the capacitor disconnected and compared to the
voltage measured with a capacitor connected that has been tested and found good.
DANGER!
HIGH VOLTAGE! With the charger operating, the charger capacitor voltage is approximately 650 volts
AC. Use extreme caution when working near capacitor terminals.
A Disconnect the transformer secondary coil leads #1 and #4 (TAN SLEEVING) from the diode terminals.
Loosen the capacitor strap and carefully disconnect the transformer capacitor coil leads from the capaci-
tor terminals.
B Refer to the transformer test voltages diagram on the wiring diagram and parts list page for the specific
part number charger and adjust the voltmeter to an appropriate AC voltage range. Attach the meter test
leads to the identified transformer coil leads.
C Checking to be sure for personal safety, and that no leads have been accidentally allowed to short, follow
the instructions below to energize the transformer primary.
• MANUAL TIMER CHARGER

Turn the timer knob to “ON” and connect the power supply cord to an outlet while recording the voltage
reading and unplug as soon as the reading is noted.
• AUTOMATIC TIMER CHARGER

Connect the DC plug to the charger receptacle and listen for the relay to “click” on 2 to 5 seconds after
the connection. Connect the AC power supply cord to an outlet while recording the voltage reading and
unplug as soon as the reading is noted.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
5-TRANSFORMER TESTING (continued)

• ALTERNATELY
The relay contacts can be bypassed to enable transformer testing when the battery system is not
present. Make up jumper leads (1 for 115 VAC, 2 for 230 VAC) with 3/16" (4.56 mm) wide flat blade
push in connectors on both ends of a piece of 14 gauge flexible wire (Fig. 5). Carefully disconnect the
AC cord lead and transformer primary lead (1 each 115 VAC, 2 each 230 VAC) from the relay terminals.
Connect the jumper lead (1 for 115 VAC, 2 for 230 VAC) according to the transformer test diagram on the
wiring diagram and parts list for the specific part number charger. Connect the AC power supply cord to
an outlet while recording the voltage reading and unplug as soon as the reading is noted (Fig. 5).
Jumper
Lead
Connected
Capacitor
Leads
Disconnected
Jumper Leads
FIGURE 5. Transformer test.
D If the AC line fuse or circuit breaker blows, the transformer is shorted internally and must be replaced.
E Check the transformer secondary coil and capacitor coil voltage and compare to voltages on the trans-
former test diagram for the specific part number charger. If the voltages are substantially lower than
those shown, the transformer is shorted internally and must be replaced.
F If the secondary coil voltage and capacitor coil voltage check good, re-test the secondary coil voltage with
the correct capacitor connected. If the secondary coil voltage is the same measured with the capacitor
disconnected, the capacitor may be open, or the capacitor coil terminals may not be making proper
contact.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
6-TEST FUSES AND DIODES
Disconnect the AC power cord and the charging cord.
A Set the multimeter to the low resistance scale (R X 1 ) or use a low voltage continuity test light.
B Excessive heat due to a loose, corroded or distressed connection can cause one or both fuse assembly
links to melt and open. Fuseholders that are worn, corroded, bent or broken can result in an open circuit
even when a good fuse is installed. Isolate the fuseholder assembly electrically and test for continuity
with a good fuse installed.
C Electrically test and visually check the fuses and fuse assembly for continuity. A single blown fuse or
fuse link is normally caused by a short circuit failure of a single diode. When both fuses or fuse links are
blown, this is usually due to a reverse polarity connection to the batteries. Test the diodes and correct
the problem before replacing the fuse.
DANGER!
Replace the fuse or fuse assembly only with the correct fuse or fuse assembly. FIRE, PROPERTY
DAMAGE AND PERSONAL INJURY CAN RESULT IF THE CHARGER IS USED WITH AN INCORRECT
FUSE INSTALLED.
D To test the diodes, disconnect one transformer secondary coil lead (TAN SLEEVING) from the diode
terminal. Using the multimeter or a low voltage continuity tester, connect one lead to the diode heatsink
plate or terminal, and the other lead to a diode terminal (Fig. 6). Note the response and then reverse the
tester leads and check each diode again.
• GOOD DIODE: When the diode shows

continuity in one direction but not the other.
• SHORTED DIODE: When the diode shows

continuity in both directions.
• OPEN DIODE: When the diode does not

show continuity in either direction.
E If the diode(s) is OPEN or SHORTED the

complete heatsink assembly with diode(s)
must be replaced.
FIGURE 6. Test diodes.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
7-CHARGER DC CIRCUIT TEST
Disconnect the AC power cord and the DC charger plug.
A Set multimeter to low resistance scale (R X 1) or use a low voltage continuity tester.
B Connect one lead of the ohmmeter or continuity tester to one of the DC charging plug contacts, and the
other to the remaining DC plug contacts and note the response. Reverse the test leads and note the
response again. The circuit should be complete in one direction only (Fig. 7 & 8).
FIGURE 7. Test charger DC circuit. The FIGURE 8. Test charger DC circuit. The
circuit conducts in one direction. circuit does not conduct in reverse
direction.
Note: When using a very sensitive ohmmeter, disconnect the control cable assembly edge connector from the
electronic timer kit.
C If the circuit does not conduct in either direction and the fuses or fuse assembly test good, individually
check the continuity of the DC output cord, ammeter, diodes and all connections.
D If the circuit conducts in both directions, a “short” exists in the charger DC circuit. First check the DC
output cord for a “short” between the two wires. Second, check if one or more of the diodes has failed in
the shorted mode.

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
8-AMMETER REMAINS AT MAXIMUM CHARGE FOR MORE THAN 30 MINUTES
This condition normally results if the charger is connected to a battery pack which is of lower system voltage
than specified in the operaters manual and / or the charger case.
CAUTION!
Do not connect the charger to, or attempt to use the charger on battery packs of different DC voltage
than specified on the front of the charger. Overheating and transformer burn-out will result.
________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
9-TEST AUTOMATIC TIMER SECTION FOR “DOES NOT TURN OFF”
A Disconnect the AC power supply cord and the DC charging plug. Remove the cover and verify that the
control cable assembly leads are securely connected in accordance with the correct wiring diagram for
the specific part number charger.
B Using the test kit, check continuity of the green sense lead between the pad on the test kit in line with the
green wire and where the sense lead connects to the diode terminal. If the circuit is “open”, replace the
control cable assembly.
C Connect the charger DC plug to the charging receptacle and then the AC power cord to turn the charger
on. Remove the automatic timer kit retaining screws and carefully slide the kit out the front of the
charger. Disconnect the edge connector from the circuit board and note if the transformer hum ceases
and the ammeter drops to zero. Does the charger now turn off?
• CHARGER DOES NOT TURN OFF: The control relay has frozen “ON”. Replace the relay with the
correct part number as specified on the correct parts list for the specific part number charger.
• CHARGER TURNS OFF: The automatic timer kit is malfunctioning. Replace the automatic timer kit with
the correct part number as specified on the correct parts list for the specific part number charger.

BATTERY CHARGER PARTS LIST
BLK
2 DIODE
4 RED OR WHT +
1
1 TIMER 3 FUSE
6 AMMETER TO DC
5
2 PLUG
-
BLK
3
WHT
4
FUSE 6
AC
INLET DIODE
PLUG
CAPACITOR 1
2 3
TRANSFORMER TEST DIAGRAM
BLK SECONDARY COIL

1
TAN
1 TIMER 3
BLK 2 SECONDARY
3 TEST POINTS
BLK
WHT
AC TAN
INLET 4
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL
2
PARTS LIST FOR APA BATTERY CHARGER

PART NUMBER 56206975 24 VOLT 10 AMP MANUAL
120 VAC 60 HZ
Item Part No. Qty Description
* 56206904 1 Heatsink Assembly, With Diodes Test Capacitor Capacitor

1 56206905 1 Ammeter Position Disconnected Connected
2 56206906 1 Timer, 12 Hour
* 56206914 1 Knob, Timer Secondary Approx. Approx.
3 56206907 1 Capacitor, 2.0 MFD, 660 VAC Coils 36 to 44 VAC 54 to 66 VAC
* 56206908 2 Bushing, 6N3-4, Insulator For Cordsets
5 56206910 1 Cordset, DC, 14/2, 108", Lester Plug Capacitor Approx.
6 56206912 2 Fuse, 15 AMP, AGC-15 Coil 395 VAC
* 56206913 2 Fuseholder, HKP-HH, With 1/4 qd Tabs
A.C. Input - 120 VAC / 60HZ
* = Not Shown
16 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST revised 8/00
RED
BLK
ELECT. GRN
TIMER
BRN
2 TRANSFORMER DIODE WHT
RELAY +
TAN
7 6 TO DC
BLK
FUSE 5 PLUG
BLK BLK
-
WHT BLK FUSE
AMMETER
AC 1
INLET TAN 6
PLUG
4 RED 6
DIODE
BLK 5
4
3 CAPACITOR
GRN 2
BRN 1

RELAY
PRIMARY COIL SECONDARY COIL

1
TAN
JUMPER BLK 2 SECONDARY

3 TEST POINTS
BLK
AC TAN 4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

PART NUMBER 56206980 24 VOLT 10 AMP AUTOMATIC
120 VAC 60 HZ
* 56206904 1 Heatsink Assembly, With Diodes

1 56206905 1 Ammeter
2 56206917 1 Electronic Timer Assembly
3 56206907 1 Capacitor, 2.0 MFD, 660 VAC Test Capacitor Capacitor
* 56206908 2 Bushing, 6N3-4, Insulator For Cordsets Position Disconnected Connected
* 56206982 1 AC Cord Strain Relief
5 56206910 1 Cordset, DC, 14/2, 108", Yellow Lester Plug Secondary Approx. Approx.
(used on 206980) Coils 36 to 44 VAC 54 to 66 VAC
* 56324306 2 DC Charger Plug Contact
(used with SB 50 small red plug) Capacitor Approx.
6 56206912 2 Fuse, 15 AMP, AGC-15 Coil 370 VAC
* 56206913 2 Fuseholder
7 56206919 1 Relay, 24VDC, SP, 15 AMP A.C. Input - 120 VAC / 60HZ
* 56206921 1 Test Kit, E.T. Bypass
* = Not Shown
revised 8/00 FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 17
BLK
2 DIODE
4 RED OR WHT +
1
FUSE
1 TIMER 3 ASSY 6 AMMETER TO DC
5
2 PLUG
-
BLK
3
WHT
AC 4
INLET DIODE
PLUG
CAPACITOR 1
2 3
BLK SECONDARY COIL

1
TAN
1 TIMER 3
BLK 2 SECONDARY
3 TEST POINTS
BLK
WHT
AC TAN
INLET 4
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL
2

120 VAC 60 HZ

Test Capacitor Capacitor
* 56373047 1 Heatsink Assembly, With Diodes Position Disconnected Connected
1 56373048 1 Ammeter
2 56206906 1 Timer, 12 Hour Secondary Approx. Approx.
* 56206914 1 Knob, Timer Coils 36 to 44 VAC 54 to 66 VAC
3 56373049 1 Capacitor, 4.0 MFD, 660 VAC
* 56373050 2 Bushing, 7W-2, Insulator For Cordsets Capacitor Approx.
4 56373051 1 Cordset, AC, 14/3, 78", Molded Plug Coil 435 VAC
5 56373053 1 Cordset, DC, 12/2, 108", SB175 Red Plug
6 56373054 1 Fuse Assembly A.C. Input - 120 VAC / 60HZ
* 56372045 1 Case Assembly
* 56373046 1 Transformer Assembly
* = Not Shown

RED
BLK
ELECT. GRN
TIMER
BRN
3 1 TRANSFORMER DIODE WHT
RELAY +
TAN
8 7 TO DC
BLK 6 PLUG
BLK BLK
-
WHT BLK
FUSE AMMETER
AC ASSY
INLET TAN
2
PLUG
5 RED 6
DIODE
BLK 5
4
3 CAPACITOR
GRN 2
BRN 1

RELAY

1
TAN

3 TEST POINTS
BLK
AC TAN 4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
1 56373056 1 Transformer Assembly Test Capacitor Capacitor

2 56373048 1 Ammeter
3 56373057 1 Electronic Timer Assembly Secondary Approx. Approx.
4 56373049 1 Capacitor, 4.0 MFD, 660 VAC Coils 36 to 44 VAC 54 to 66 VAC
* 56373050 2 Bushing, 7W-2, Insulator For Cordsets
5 56373058 1 Cordset, AC, 14/3, 78", Molded Plug Capacitor Approx.
6 56373053 1 Cordset, DC, 12/2, 108", SB175 Red Plug Coil 430 VAC
7 56373054 1 Fuse Assembly
8 56206919 1 Relay, 24VDC, SP, 15 AMP A.C. Input - 120 VAC / 60HZ
* 56373059 1 Control Cable Assembly
* = Not Shown

BLK
RED
ELECT. GRN
TIMER
BRN RELAY
3 DIODES
ORN TRANSFORMER WHT
+
TAN
2 4 TO DC
BLK 5 PLUG
BLK BLK
-
WHT BLK
FUSE AMMETER
AC ASSY
INLET TAN
6
PLUG
DIODES
CAPACITOR

RELAY

1
TAN

3 TEST POINTS
BLK
AC TAN 4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
Item Part No. Qty Description Test Capacitor Capacitor

Position Disconnected Connected
1 56388557 1 Capacitor
2 56206919 1 Relay, 24VDC, 15 AMP Secondary Approx. Approx.
4 56373054 1 Fuse Assembly Coils 36 to 44 VAC 54 to 66 VAC
5 56373053 1 DC Cordset, SB-175 Red Plug
* 56373055 1 Control Cable A.C. Input - 120 VAC / 60HZ
* 56373050 2 Bushing, 7W-2
6 56373069 1 Ammeter
* 56373057 1 Electronic Timer Kit
* = Not Shown
BLK
2 DIODE
4 RED OR WHT +
1
FUSE
1 TIMER 3 ASSY 6 AMMETER TO DC
5
2 PLUG
-
BLK
3
WHT
AC 4
INLET DIODE
PLUG
CAPACITOR 1
2 3
BLK SECONDARY COIL

1
TAN
1 TIMER 3
BLK 2 SECONDARY
3 TEST POINTS
BLK
WHT
AC TAN
INLET 4
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL
2

120 VAC 60 HZ

1 56373048 1 Ammeter
2 56206906 1 Timer, 12 Hour Secondary Approx. Approx.
* 56206914 1 Knob, Timer Coils 55 to 65 VAC 83 to 97 VAC
* = Not Shown

RED
BLK
ELECT. GRN
TIMER
BRN
3 1 TRANSFORMER DIODE WHT
RELAY +
TAN
8 7 TO DC
BLK 6 PLUG
BLK BLK
-
WHT BLK
FUSE AMMETER
AC ASSY
INLET TAN
2
PLUG
5 RED 6
DIODE
5
BLK 4
CAPACITOR
GRN 3
2
BRN 1

RELAY

1
TAN

3 TEST POINTS
BLK
AC TAN 4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

PART NUMBER 56395101 (replaces part numbers 56372947 & 56395347)
36 VOLT, 20 AMP, AUTOMATIC 120 VAC 60 HZ
* 56373064 1 Case Assembly Test Capacitor Capacitor

1 56373065 1 Transformer Assembly Position Disconnected Connected
2 56373048 1 Ammeter Secondary Approx. Approx.
3 56373066 1 Electronic Timer Assembly Coils 55 to 65 VAC 83 to 97 VAC
8 56206919 1 Relay, 24VDC, SP, 15 AMP
* = Not Shown
RED
BLK
ELECT. GRN
TIMER
BRN
2 TRANSFORMER DIODE WHT
RELAY +
TAN
7 6 TO DC
BLK 5 PLUG
BLK BLK
-
WHT BLK
FUSE AMMETER
AC ASSY
INLET TAN
1
PLUG
4 RED 6
DIODE
5
BLK 4
CAPACITOR
GRN 3
2
BRN 1

RELAY

1
TAN

3 TEST POINTS
BLK
AC TAN 4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
* 56388555 1 Heatsink Assembly, With Diodes Test Capacitor Capacitor

3 56388557 1 Capacitor, 4.0 MFD, 660 VAC Secondary Approx. Approx.
* 56373050 2 Bushing, 7W-2, Insulator For Cordsets Coils 55 to 65 VAC 83 to 97 VAC
4 56373058 1 Cordset, AC, 14/3, 78", Molded Plug
5 56373063 1 Cordset, DC, 12/2, 108", SB175 Plug Capacitor Approx.
6 56373054 1 Fuse Assembly Coil 420 VAC
7 56206919 1 Relay, 24VDC, SP, 15 AMP
* 56206921 1 Test Kit, E.T. Bypass A.C. Input - 120 VAC / 60HZ
* = Not Shown

BLK
RED
ELECT. GRN
TIMER
BRN RELAY
3 DIODES
ORN TRANSFORMER WHT
+
TAN
2 7 TO DC
BLK 6 PLUG
BLK BLK -
WHT BLK
FUSE AMMETER
AC ASSY
INLET TAN
5
PLUG 4
DIODES
CAPACITOR

RELAY

1
TAN

3 TEST POINTS
BLK
AC TAN
4
INLET
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
1 56388557 1 Capacitor
2 56206919 1 Relay, 24VDC, 15 AMP
3 56373066 1 Electronic Timer Kit
4 56373058 1 AC Cordset 14/3, 78", Molded Plug
Secondary Approx. Approx.
* 56373050 2 Bushing, 7W-2
Coils 55 to 65 VAC 83 to 97 VAC
5 56373070 1 Ammeter
6 56373074 1 Cordset, DC
7 56373071 1 Fuse Assembly
* = Not Shown

6
3
200-220/221-250
VAC INPUT
AC
7 5
TRANSFORMER SHUNT
FUSE SCR BLACK
BLACK BROWN TAN RED +
5 1 DC AMMETER TO DC
GREEN 6 2 BLACK
FUSE PLUG
-
4
200-221 BLACK BLACK
SETTING 7 3 BLACK
BLACK
WHITE
YELLOW
4 SCR
8
RED
221-250
9
TAN
ORANGE
9
7
1
SETTING
WHITE
AC
WHITE
WHITE
FUSE 10 6
BLACK
5
WHITE
200-221
WHITE
11 4
SETTING YELLOW 3
SHOWN 12
BROWN 2
8 13 BROWN
6 2
TAN
1
14
ELECTRIC
WHITE
TIMER

RELAY
JUMPER
BLACK PRIMARY COIL SECONDARY COIL

1
AC GREEN
5 3
INLET
PLUG 4 2
RED OR 2 SECONDARY
WHITE 3 TEST POINTS
JUMPER
4
CAPACITOR
TEST POINTS
CAPACITOR COIL

221-250 VAC 50-60 HZ
1 56409699 1 Ammeter Test Capacitor Capacitor

* 56409700 2 Heatsink Assembly Position Disconnected Connected
* 56409702 3 Bushing, Insulator Secondary Approx. Approx.
* 56409703 1 Control Cable Assembly Coils 55 to 65 VAC 83 to 97 VAC
3 56409704 1 Cordset, AC
4 56409706 1 Cordset, DC, SB-175 Plug Capacitor Approx.
* 56409707 1 Fuseholder, 30 Amp, 600 Volt, 2 Pole Coil 410-470 VAC
5 56409708 1 Fuse, DC, 125 Amp, JJN-125
6 56409709 2 Fuse, AC, 25 Amp, FLM-25 A.C. Input - 230 VAC / 50HZ
7 56409710 1 Shunt, Electronic
8 56409711 1 Terminal Strip, 2 Pole
* = Not Shown
ELECTRONIC TIMER
BLACK
RED
GREEN
2
TRANSFORMER DIODE
TAN RED OR
1 WHITE
+
1
3 2 FUSES TO DC PLUG 5
BLACK
BLACK
-
2
BLACK
4 3
AMMETER
6 1
DIODE
BLACK LOW BATTERY 4
VOLTAGE START
7 TAN
GREEN
SWITCH 3
115 VAC WHITE
INPUT CAPACITOR
PLUG
RELAY
JUMPER

1
3
WHITE 1
2 SECONDARY
GREEN 2 3 TEST POINTS
BLACK
AC
INLET 4
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
* 56411083 1 Heatsink Assembly, W/Diodes Test Capacitor Capacitor
3 56411086 1 Capacitor, 2.0 MFD, 660 VAC Secondary Approx. Approx.
* 56411087 2 Bushing, 6N3-4, Insulator for Cordset Coils 17 to 23 VAC 27 to 33 VAC
4 56411088 1 Cordset, AC
5 56411089 1 Cordset, DC W/SB-50 Amp Grey Plug Capacitor Approx.
* 56411090 2 Fuseholder Assembly Coil 410-470 VAC
6 56478271 2 Fuse, 15 Amps
7 56411091 1 Switch, Rocker A.C. Input - 120 VAC / 60HZ
* = Not Shown
ELECTRONIC TIMER 2
BLACK
RED
GREEN
RELAY TRANSFORMER DIODE
TAN
ORANGE
9 1 WHITE
+
CIRCUIT
BREAKERS TO DC
BROWN
2 PLUG 5
BLACK
BLACK
BLACK WHITE -
BLACK
BLACK 3
AMMETER
6 1
10
4 7 DIODE
4
8 LOW BATTERY
TAN
BLACK
VOLTAGE START
SWITCH
3
GREEN
WHITE CAPACITOR
115 VAC
INPUT
PLUG

RELAY
JUMPER

1
3
WHITE 1
2 SECONDARY
GREEN 2 3 TEST POINTS
BLACK
AC
INLET 4
PLUG
CAPACITOR
TEST POINTS
CAPACITOR COIL

120 VAC 60 HZ
* 56411647 1 Heatsink Assembly, W/Diodes Test Capacitor Capacitor
1 56411648 1 Ammeter
* 56411651 2 Bushing, SR-5KN-4, Insulator for DC Cordset Secondary Approx. Approx.
4 56411653 1 Cordset, AC Coils 17 to 23 VAC 27 to 33 VAC
5 56411654 1 Cordset, DC W/SB-50 Amp Red Plug
6 56478655 1 Switch Assembly
7 56411657 1 Fuse, 5 Amps, MDA-5 Capacitor Approx.
9 56411659 1 Relay, 12V / 10A, SPST Coil 410-470 VAC
* 56411087 1 Bushing 6N3-4 Insulator Cordset
* 56411646 1 Trasformer Assembly
* = Not Shown

7
DC
FUSE
AMMETER 1
2 3 BLACK BLACK
1 4
PRI PRI
TRANSFORMER BLACK
SEC SEC
8 5
9 6
10 TAN
7 2
11 12 13 14 BLACK
BROWN
HEATSINKS
SCR
ASS'Y
TAN
8 4
5 9 6 7 11
BLACK 2
10 12
BROWN
AC 13 BLACK (-)
FUSE 200- 220- -
8 219 240 14 SHUNT BLACK (+) TO DC
6
AC + PLUG
FUSEHOLDER
INPUT 4 OUTPUT
VOLTAGE RED BUSHINGS
9 9
OR RED
ADJUST ORANGE
WHITE
7
(220-240 WHITE 6
BLACK
SETTING
4 SHOWN)
BLACK 5
WHITE 4 ELECTRONIC TIMER
GREEN
INPUT YELLOW 3
CASE GROUND
BUSHING BROWN 2 3
INPUT INPUT VOLTAGE BROWN 1
CORDSET 200-219 OR 220-240 VAC
5

RELAY
JUMPER
BLACK PRIMARY COIL SECONDARY COIL

1
AC GREEN
5 3
INLET
PLUG 4 2
RED OR 2 SECONDARY
WHITE 3 TEST POINTS
JUMPER
4
CAPACITOR
TEST POINTS
CAPACITOR COIL

221-250 VAC 50-60 HZ
1 56409795 1 Ammeter Test Capacitor Capacitor
2 56409700 2 Heatsink Assembly Position Disconnected Connected
4 56409702 3 Bushing, Insulator
Secondary Approx. Approx.
Coils 55 to 65 VAC 83 to 97 VAC
5 56409704 1 Cordset, AC
6 56409706 1 Cordset, DC, SB-175 Plug
* 56409707 1 Fuseholder, 30 Amp, 600 Volt, 2 Pole Capacitor Approx.
7 56409708 1 Fuse, DC, 125 Amp, JJN-125 Coil 410-470 VAC
8 56409709 2 Fuse, AC, 25 Amp, FLM-25
* 56409798 2 Scr Assy, 55A/400V, with wires A.C. Input - 230 VAC / 50HZ
* 56409799 1 Electronic Control/Timer Assy 36V, 38/14 Amps
9 56409800 1 Input Voltage Adjust Terminal Block, 30A/300V, 2 Pole

POWER THERMAL
SWITCH PROTECTOR TRANSFORMER
BLACK
FUSE
GREEN CONTROL WHITE
BOARD +
WHITE
DC
AC OUTPUT
INPUT
BLACK -

PART NUMBER 56205983 (replaces part number 56206981)
24 VOLT 12 AMP AUTOMATIC 120 VAC 60 HZ
Part No. Qty Description
56411087 1 Bushing 6N3-4 Insulator Cordset
56205148 2 Case Assembly
56205153 1 Control Board Assembly
56205150 3 Cordset AC 18/3 102" w/Plug
56205152 1 Cordset DC 14/2 108" w/SB50 Red Plug
56205154 1 Power Switch
56205149 1 Transformer
CAPACITOR TAN HEATSINK ASSEMBLIES

WITH DIODES
ELECTRONIC
TIMER KIT TAN
TAN
RELAY BLACK
DC OUTPUT POLARITY
RED POSITIVE: +, WHITE OR RED.
1 4 TAN NEGATIVE: -, BLACK
TRANSFORMER
DC CORDSET
1 SECONDARY 3 2 BLACK
WHITE OR RED (+)
PRIMARY +
BLACK
3 -
2
BLACK (-)
TO
GROUNDED TAN BATTERIES
WHITE
AC INPUT
TAN BLACK
GREEN
AC
CORDSET FUSE AMMETER
CASE GROUND ASSEMBLY

PART NUMBER 56412272 24 VOLT, 36 to 8 AMP AUTOMATIC
120 VAC 60 HZ
56373070 1 Ammeter 50 Amp w/Mounting Studs
56373073 2 Heatsink Assy w/2 Diodes in Parallel
56388557 1 Capacitor 6MFD 660 VAC
56409702 3 Bushing, Insulator
56412451 1 Case Assembly
56412457 1 Cordset, AC 14/3 86" w/125V/15a Plug
56412456 1 Cordset Bushing 8P-2
56412458 1 Cordset DC 10/2 108" w/SB175 Red Plug
56373071 1 Fuse Assembly
56412454 2 Timer Kit 24 VDC 120 VAC
56412455 2 Timer Kit Relay 24 VDC 120 VAC
56412452 1 Transformer Assembly
CAPACITOR
HEATSINK ASS'Y W/DIODES
ELECTRONIC
TIMER ASS‘Y
TAN
TAN
TAN
BLACK
CABLE ASS‘Y
5
CONTROL
WHITE OR RED (+)

4 TAN
3
2 GREEN 1
4
BROWN
RED
TRANSFORMER
OUTPUT POLARITY:
NEGATIVE: -, OR BLACK
RED
TAN SECONDARY 3 2 POSITIVE: +, RED OR WHITE

TAN RELAY +
-
BLACK
BLACK (-) OUTPUT TO
BUSHING BATTERIES
BLACK
PRIMARY
OUTPUT CORDSET
FUSE AMMETER
% ' ) * $ "
ASSEMBLY
AC INPUT
INPUT BUSHING BLACK OR BROWN
GREEN OR GREEN W/YELLOW
RED OR WHITE OR BLUE
INPUT
CORDSET
CASE GROUND

230 VAC 50 HZ
56373066 1 Timer Kit
56373070 1 Ammeter
56373073 1 Heatsink Assembly w/ Diodes
56388557 1 Capacitor, 6 MFD, 660 VAC
56373074 1 Cordset, DC, 10/2, 108", SB175 Plug
CAPACITOR
ELECTRONIC
TIMER ASS’Y
TAN
TAN
TAN
CABLE ASS‘Y
5
BLACK
CONTROL
4 TAN
3
WHITE OR RED (+)

2 GREEN 1
1 4
BROWN
RED
TRANSFORMER
OUTPUT POLARITY:
TAN NEGATIVE: -, OR BLACK
SECONDARY 3 2
POSITIVE: +, RED OR WHITE
RED
TAN RELAY +
-
BLACK BLACK (-) TO
OUTPUT
PRIMARY BUSHING BATTERIES
BLACK
OUTPUT
CORDSET
FUSE AMMETER
ASSEMBLY
7 9 A B 6 4
AC
INPUT INPUT
BUSHING BLACK OR BROWN
INPUT
CORDSET
CASE GROUND

230 VAC 50 HZ
56388557 1 Capacitor, 6 MFD, 660 VAC/70C, 600 VAC/90C
56373047 1 Heatsink Assembly, w/ Diodes
56409702 1 Insulator Bushing, for 12/2 DC Cordset
CAPACITOR
ELECTRONIC
TIMER ASS’Y
TAN
TAN
TAN
CABLE ASS‘Y
5
BLACK
CONTROL
4 TAN
3
WHITE OR RED (+)

2 GREEN 1
1 4
BROWN
RED
TRANSFORMER
OUTPUT POLARITY:
SECONDARY 3 2
RED
TAN RELAY +
-
BLACK BLACK (-) TO
OUTPUT
BLACK
OUTPUT
CORDSET
FUSE AMMETER
ASSEMBLY
7 9 A B 6 4
AC
INPUT INPUT
INPUT
CORDSET
CASE GROUND

230 VAC 50 HZ
56373070 1 Ammeter
CAPACITOR
ELECTRONIC
TIMER ASS’Y
TAN
TAN
TAN
CABLE ASS‘Y
5
BLACK
CONTROL
4 TAN
3
WHITE OR RED (+)

2 GREEN 1
1 4
BROWN
RED
TRANSFORMER
OUTPUT POLARITY:
SECONDARY 3 2
RED
TAN RELAY +
-
BLACK BLACK (-) TO
OUTPUT
BLACK
OUTPUT
CORDSET
FUSE AMMETER
ASSEMBLY
7 9 A B 6 4
AC
INPUT INPUT
INPUT
CORDSET
CASE GROUND

230 VAC 50 HZ
56373070 1 Ammeter
WITH DIODES
ELECTRONIC
TIMER KIT TAN
TAN
RELAY BLACK
DC OUTPUT POLARITY
TRANSFORMER
DC CORDSET
WHITE OR RED (+)
PRIMARY +
BLACK
3 -
2
BLACK (-)
TO
WHITE
AC INPUT
TAN BLACK
GREEN
AC
PARTS LIST FOR LESTER BATTERY CHARGER

120 VAC 60 HZ
56373073 2 Heatsink Assembly w/ 2 Diodes in Parallel
56373070 1 Ammeter, 50 Amp, w/ Corner Mounting Studs
56409702 1 Cordset Bushing, 7W-2, for Input Cordset
56412456 1 Cordset Bushing, 8P-2, for Output Cordset
56412457 1 AC Cordset, 14/3, 86", w/ 125V/15A Plug
CAPACITOR HEATSINK ASSEMBLY
WITH DIODES
ELECTRONIC TAN
TIMER KIT TAN
TAN
RELAY BLACK
RED TAN
GREEN*
1
4
TRANSFORMER
DC CORDSET
1 SECONDARY 3 2
BLACK WHITE OR RED (+)
PRIMARY +
2 3 BLACK -
BLACK (-)
TO
GROUNDED BATTERIES
WHITE
AC INPUT TAN
GREEN TAN BLACK
AC *GREEN WIRE NOT USED FUSE

CORDSET AMMETER
ON SOME MODELS. ASSEMBLY
CASE GROUND

115 VAC 60 HZ
56373047 1 Heatsink Assembly, w/Doiodes
56412454 1 Relay, Timer Kit, 24 VDC
56409702 1 Bushing, 7W-2, Insulator for Cordsets
56373063 1 Cordset, DC, w/175 Amp Plug, Gray, 101"
56373053 1 Cordset, DC, w/175 Amp Plug, Red, 101"
DIODE HEATSINK ASSEMBLY
CAPACITOR
ELECTRONIC
TIMER ASSEMBLY
TAN TAN
WHITE OR RED (+)

TAN
CABLE ASSEMBLY
5 BLACK
CONTROL
4 RED
3
TAN
2 GREEN DC CORDSET
1
1 4
OUTPUT
ORANGE BROWN BUSHING
TRANSFORMER
+
-
RELAY
TAN SECONDARY 3 2
TO
BATTERIES
BLACK (-)
TAN
BLACK
BLACK
PRIMARY
GROUNDED
AC INPUT
GREEN BLACK
WHITE
AC INPUT
CORDSET BUSHING FUSE AMMETER

120 VAC 60 HZ
56373047 1 Heatsink Assembly w/Diodes
56409702 1 Bushing, 7W-2, Insulator for DC Cord
56206919 1 Relay, 24 VDC, SPST, 15 Amp
56373049 1 Capacitor, 4.0 MFD, 660 VAC
POWER THERMAL
SWITCH PROTECTOR TRANSFORMER
BLACK
FUSE
GREEN CONTROL WHITE
BOARD +
WHITE
DC
AC OUTPUT
INPUT
BLACK -

120 VAC 60 HZ
56205149 1 Transformer
56205154 1 Power Switch
56411087 2 Bushing, Strain Relief, For Cords
56205150 1 Cordset, AC, 18/3, 102", w/ Molded Plug
56205152 1 Cordset, DC, 14/2, 108", w/ SB50 Red Plug
WITH DIODES
ELECTRONIC
TIMER KIT TAN
TAN
RELAY BLACK
DC OUTPUT POLARITY
TRANSFORMER
DC CORDSET
WHITE OR RED (+)
PRIMARY +
BLACK
3 -
2
BLACK (-)
TO
WHITE
AC INPUT
TAN BLACK
GREEN
AC

120 VAC 60 HZ
56412452 1 Transformer Assembly
56412454 1 Timer Kit, 24 VDC, 120 VAC
56412455 1 Timer Kit, Relay 24 VDC, SPSTNO, 120 VAC
56409702 1 Cordset Bushing, 7W-2, for Input Cordset
56412456 1 Cordset Bushing, 8P-2, for Output Cordset
56412457 1 AC Cordset, 14/3, 86" w/ 125V/15A Plug
56412458 1 DC Cordset, 10/2, 108", w/ SB175 Red Plug
56373074 1 DC Cordset, 10/2, 108", w/SB175 Gray Plug
POWER AC VOLTAGE *
SWITCH SELECTOR AC SHUNT DC
FUSE SCR OUTPUT
SWITCH BLACK BLACK WHITE
9 40 AMP
+
1 AMMETER
BLACK CIRCUIT BREAKER
BLACK 1b
10 BLACK
BLACK
-
1 BLACK BLACK
GREEN 2
1a BROWN 11
BROWN
YELLOW
WHITE BROWN
GRAY
TRANSFORMER
100-125 2b SCR
2 3 12
200-225
VAC BLACK RED
R 9
INPUT ORANGE
7
BROWN
AC BLUE
WHITE FUSE 4 6
WHITE BLACK
5
* SHOWN IN BLUE 4
100-125 VOLT YELLOW
3
POSITION 5 BROWN
2
BROWN 1
6
ELECTRONIC
7 TIMER
8
BLUE
NATURAL
BLUE

100, 125 or 200-250 VAC / 50 or 60 HZ
56373069 1 Ammeter
56409702 1 Bushing, Insulator, 7W-2, for DC Cordset
56206913 2 Fuseholder
CAPACITOR HEATSINK ASSEMBLY
WITH DIODES
ELECTRONIC TAN
TIMER KIT TAN
TAN
RELAY BLACK
RED TAN
GREEN*
1
4
TRANSFORMER
DC CORDSET
1 SECONDARY 3 2
BLACK WHITE OR RED (+)
PRIMARY +
2 3 BLACK -
BLACK (-)
TO
GROUNDED BATTERIES
WHITE
AC INPUT TAN
GREEN TAN BLACK
AC *GREEN WIRE NOT USED FUSE

CORDSET AMMETER
ON SOME MODELS. ASSEMBLY
CASE GROUND

115 VAC 60 HZ
56373047 1 Heatsink Assembly, W/Diodes
56373069 1 Ammeter, 0-30 Amp
56373051 1 Cordset, AC, 14/3, 80", Molded Plug
56373063 1 Cordset, DC, 12/2, 108", SB175Gray Plug
DIODE HEATSINK ASSEMBLY
CAPACITOR
ELECTRONIC
TIMER ASSEMBLY
TAN TAN
WHITE OR RED (+)

TAN
CABLE ASSEMBLY
5 BLACK
CONTROL
4 RED
3
TAN
2 GREEN DC CORDSET
1
1 4
OUTPUT
ORANGE BROWN BUSHING
TRANSFORMER
+
-
RELAY
TAN SECONDARY 3 2
TO
BATTERIES
BLACK (-)
TAN
BLACK
BLACK
PRIMARY
GROUNDED
AC INPUT
GREEN BLACK
WHITE
AC INPUT
CORDSET BUSHING FUSE AMMETER

120 VAC 60 HZ
56373047 1 Heatsink Assembly w/Diodes
56373069 1 Ammeter, 30 Amp, Corner Mount
56411650 1 Capacitor, 3.0 MFD, 660 VAC
POWER AC VOLTAGE *
SWITCH SELECTOR AC SHUNT DC
FUSE SCR OUTPUT
SWITCH BLACK BLACK WHITE
9 40 AMP
+
1 AMMETER
BLACK CIRCUIT BREAKER
BLACK 1b
10 BLACK
BLACK
-
1 BLACK BLACK
GREEN 2
1a BROWN 11
BROWN
YELLOW
WHITE BROWN
GRAY
TRANSFORMER
100-125 2b SCR
2 3 12
200-225
VAC BLACK RED
R 9
INPUT ORANGE
7
BROWN
AC BLUE
WHITE FUSE 4 6
WHITE BLACK
5
* SHOWN IN BLUE 4
100-125 VOLT YELLOW
3
POSITION 5 BROWN
2
BROWN 1
6
ELECTRONIC
7 TIMER
8
BLUE
NATURAL
BLUE

115 or 230 VAC / 50 or 60 HZ

56373069 1 Ammeter
56409702 1 Bushing, Insulator, 7W-2, for DC Cordset
56206913 1 Fuseholder
WITH DIODES
ELECTRONIC
TIMER KIT TAN
TAN
RELAY BLACK
DC OUTPUT POLARITY
TRANSFORMER
DC CORDSET
WHITE OR RED (+)
PRIMARY +
BLACK
3 -
2
BLACK (-)
TO
WHITE
AC INPUT
TAN BLACK
GREEN
AC

120 VAC 60 HZ
56388557 1 Capacitor, 6MFD, 660 VAC
56409702 1 Cordset Bushing, 7W-2, for 14/3 Input Cordset
56412456 1 Cordset Bushing, 8P-2, for 10/2 Output Cordset
56373074 1 DC Cordset, 10/2, 108", w/ SB175 Gray Plug
Nilfisk-Advance, Inc.
14600 21st Avenue North
Plymouth, MN, 55447-3408
www.nilfisk-advance.com
Phone: 800-989-2235
Fax: 800-989-6566
©2000 Nilfisk-Advance, Inc.,
Plymouth, MN 55447-3408
Printed in the U.S.A.

Automatic Manual Chargers

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Automatic Manual Chargers

Încărcat de

Drepturi de autor:

Formate disponibile

Battery Chargers

SERVICE MANUAL / PARTS LIST

Revised 8/00 Form Number 56041170

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 45

GENERAL SAFETY INSTRUCTIONS

Remove all jewelry when working near electrical components.

Incorrect assembly may result in a risk of electric shock or fire.

2 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

TRANSFORMER / RECTIFIER OR POWER SECTION

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 3

TRANSFORMER / RECTIFIER OR POWER SECTION (continued)

ON/OFF CONTROL SECTION

The fully automatic timer section has three main components.

4 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

AUTOMATIC TIMER BATTERY CHARGER TROUBLESHOOTING

Malfunction Descrip1ion Test Procedures / Section Number

Transformer hums but no ammeter indication. Test Charger DC Circuit / 7.

Fuse blows as soon as DC plug is connected Test Charger DC Circuit / 7.

Ammeter remains pegged at maximum Check Battery System Voltage / 8.

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 5

MANUAL TIMER BATTERY CHARGER TROUBLESHOOTING

Malfunction Description Test Procedures / Section Number

Fuse blows as soon as the charger is Test Fuses and Diodes / 6.

Ammeter remains pegged at maximum charge Check Battery System Voltage / 8.

Charger does not turn off. Replace Manual Timer.

6 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

1-CHECKING FOR COMPLETE ELECTRICAL CONNECTION TO THE BATTERIES

FIGURE 1. Testing for complete electrical connection to the battery system.

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 7

2-TEST FOR PROPER FUNCTIONING OF AUTOMATIC TIMER COMPONENTS

B Remove the retaining screws and slide the

FIGURE 2. Insert the test kit.

C Measure DC voltage across the pads on the

D Measure DC voltage across the pads on the

FIGURE 3. Measure battery system voltage

8 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

3-TEST AC POWER CIRCUIT

• MANUAL TIMER CHARGER

FIGURE 4. Test AC circuit for continuity.

• AUTOMATIC TIMER CHARGER

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 9

4-TEST THE CAPACITOR

B If the capacitor is “Open” or “Shorted” it must be replaced.

10 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

• MANUAL TIMER CHARGER

• AUTOMATIC TIMER CHARGER

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 11

5-TRANSFORMER TESTING (continued)

FIGURE 5. Transformer test.

12 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

6-TEST FUSES AND DIODES

Disconnect the AC power cord and the charging cord.

• GOOD DIODE: When the diode shows

• SHORTED DIODE: When the diode shows

• OPEN DIODE: When the diode does not

E If the diode(s) is OPEN or SHORTED the

FIGURE 6. Test diodes.

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 13

7-CHARGER DC CIRCUIT TEST

Disconnect the AC power cord and the DC charger plug.

14 - FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST

8-AMMETER REMAINS AT MAXIMUM CHARGE FOR MORE THAN 30 MINUTES

9-TEST AUTOMATIC TIMER SECTION FOR “DOES NOT TURN OFF”

FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 15